Suspension packaging assembly

ABSTRACT

A suspension package assembly can include a package member and a stretchable retention member. The package member and a stretchable retention member cooperate to suspend at least one article. At least one article can be held securely between the retention member and a base member of the foldable member. The pocket of the retention member can be positioned over the foldable portions of the package member. The foldable portions can fit into the pockets and then can be folded so as to generate tension in the retention member. Coupling assemblies inhibit relative movement of the retention member and the packaging member.

PRIORITY INFORMATION

This application is a continuation application of U.S. patent application Ser. No. 11/633,712 filed Dec. 5, 2006, the entire contents of which is hereby expressly incorporated by reference.

BACKGROUND OF THE INVENTIONS

1. Field of the Inventions

The present inventions are directed to a package assembly. In particular, the present inventions are directed to a suspension package assembly that includes a stretchable retention member and a packaging member.

2. Description of the Related Art

Protective packaging devices are often used to protect goods from shocks and impacts during shipping or transportation. For example, when transporting articles that are relatively fragile, it is often desirable to cushion the article inside a box to protect the article from a physical impact with the inner walls of the box that might be caused by shocks imparted to the box during loading, transit, and/or unloading.

In most cases, some additional structure is used to keep the article from moving uncontrollably within the box. Such additional structures include paper or plastic packing material, structured plastic foams, foam-filled cushions, and the like. Ideally, the article to be packaged is suspended within the box so as to be spaced from at least some of the walls of the box, thus protecting the article from other foreign objects which may impact or compromise the outer walls of the box.

U.S. Pat. No. 6,675,973 discloses a number of inventions directed to suspension packaging assemblies which incorporate frame members and one or more retention members. For example, many of the embodiments of the U.S. Pat. No. 6,675,973 include the use of a retention member formed of a resilient material. Additionally, some of the retention members include pockets at opposite ends thereof.

In several of the embodiments disclosed in the U.S. Pat. No. 6,675,973, free ends of the frame members are inserted into the pockets of the retention member. The free ends of the frame member are then bent, pivoted, or folded to generate the desired tension in the retention member. Because the retention member is made from a resilient material, the retention member can stretch and thus provide a mechanism for suspending an article to be packaged, for example, within a box.

SUMMARY OF THE INVENTIONS

An aspect of at least one of the embodiments disclosed herein includes the realization that certain aspects of packaging materials can be improved by delivering the assembly to the customer in a state which reduces the number of components that the customer has to connect to use the packaging materials.

Additional advantages can be achieved where the processes or devices used to assemble the materials do not add weight to the materials and/or do not require the use of additional techniques that are not already used for manufacturing the other components of the materials.

Thus, in accordance with an embodiment, a packaging kit for packaging an article and maintaining the article in a position spaced from a wall of a container can be provided. The kit can include a resilient member comprising a body portion and first and second pockets disposed at opposite ends of the body portion. A substantially rigid member can comprise a base member sized to engage the article. A first foldable portion and a second foldable portion can be configured to be pivotable relative to the base member, at least a portion of the first foldable portion configured to fit with the first pocket and at least a portion of the second foldable portion configured to fit within the second pocket. Additionally, at least one coupling assembly can be configured to limit relative movement between the resilient member and the rigid member, the at least coupling assembly comprising an aperture in the rigid member and a coupler, the coupler extending through the aperture and connected to the resilient member.

In accordance with another embodiment, a package assembly for packaging an article and maintaining the article in a position spaced from a wall of a container can be provided. The package assembly can comprise a resilient member comprising a first sheet and a second sheet. A substantially rigid member can comprise a base member configured to engage the article, a first foldable portion and a second foldable portion configured to be pivotable with respect to the base member, the first foldable portion, and at least one coupling assembly configured to limit relative movement between the resilient member and the rigid member, the at least one coupling assembly comprising an aperture in the rigid member and a coupler, the coupler extending through aperture and connecting the first sheet and the second sheet.

In accordance with yet another embodiment, a method of manufacturing a packaging assembly can be provided. The method can comprise forming an aperture in a base member, placing a first resilient member on a first side of the aperture, placing a second resilient member on a second side of the aperture, and connecting the first and second resilient members through the aperture.

In accordance with yet a further embodiment, a package assembly can comprise a first resilient sheet portion, a second resilient sheet portion, a substantially rigid member including an aperture, and means for connecting the first resilient sheet portion to the second resilient sheet portion through the aperture.

For purposes of summarizing the inventions and the advantages achieved over the prior art, certain objects and advantages of the inventions have been described hereinabove. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the inventions. Thus, for example, those skilled in the art will recognize that the inventions may be embodied or carried out in a manner that achieves or optimizes one advantage or a group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

All of these embodiments are intended to be within the scope of the inventions disclosed herein. These and other embodiments of the inventions will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the inventions not being limited to any particular preferred embodiments disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the inventions are described below with reference to the drawings of several embodiments of the present package assemblies and kits which are intended to illustrate, but not to limit, the inventions. The drawings contain the following figures:

FIG. 1 is a plan view of a packaging member in an unfolded and unassembled state, the packaging member having foldable portions disposed around the periphery of a central base member;

FIG. 2 is a plan view of a retention member having a pair of opposing pockets;

FIG. 3 is a top plan view of a package assembly having the retention member attached to the packaging member, and the package assembly is in an unfolded state with an article disposed between a surface of the retention member and a surface of the packaging member;

FIG. 4 is a cross-sectional view of an optional feature of the package assembly of FIG. 3 taking along the line 4-4 in FIG. 3;

FIG. 5 is a bottom plan view of the package assembly of FIG. 3;

FIG. 6 is a side elevational view of the package assembly and an article held therein;

FIG. 7 is a top plan view of the package assembly of FIG. 6 in a partially folded state;

FIG. 8 is a side elevational view of the package assembly of FIG. 6 in a partially folded state;

FIG. 9 is a side elevational view of the package assembly of FIG. 6 in a fully folded state;

FIG. 10 is a top plan view of the package assembly of FIG. 6 in a fully folded state;

FIG. 11 is a partial cross-sectional view of the package assembly in a fully folded state, and the package assembly is disposed within a container;

FIG. 12A is a side elevational view of a packaging system in an open position, and the packaging system is configured to form a retention member on a packaging member;

FIG. 12B is a side elevational view of the packing system of FIG. 12A in a closed position;

FIGS. 13A-13C are side elevational views of another packaging system for producing a package assembly;

FIG. 14A is a top plan view of a package assembly made by the packaging system of FIGS. 13A-13C;

FIG. 14B is a bottom plan view of the package assembly of FIG. 14A; and

FIG. 15 is a top plan view of a modification of the package assembly of FIGS. 1-15.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An improved package assembly is disclosed herein. The package assembly includes an improved structure which provides new alternatives to known suspension packaging systems.

In the following detailed description, terms of orientation such as “upper,” “lower,” “longitudinal,” “horizontal,” “vertical,” “lateral,” “midpoint,” and “end” are used herein to simply the description in the context of the illustrated embodiments. Because other orientations are possible, however, the present inventions should not be limited to the illustrated orientations. Additionally, the term “suspension” is not intended to require that anything, such as an article to be packaged, is suspended above anything. Rather, the terms “suspended” as used herein, is only intended to reflect that such an article is held in a position spaced from another member, such as at least one of the walls of a container or box. Those skilled in the art will appreciate that other orientations of various components described herein are possible.

With reference to FIG. 1, a packaging member 100 is illustrated therein in an unfolded state and is constructed in accordance with an embodiment. Generally, the packaging member 100 includes a base member 120 and a pair of opposing foldable portions 130, 132. The base member 120 is configured to engage or provide support for one or more articles to be packaged.

In some embodiments, the foldable portions 130, 132 are configured to increase a tension in a resilient member (FIG. 2) for holding one or more articles in a desired position relative to the base member, an exemplary position being shown in FIG. 3.

In some environments of use, opposing lateral wall portions 140, 142 can be manipulated to form lateral side wall that suspend the base member 120 (see FIG. 11). The lateral wall portions can be configured to extend generally vertically on either side of the base member 120.

With continued reference to FIG. 1, the packaging member 100 can be constructed from various materials, including but without limitation, pulp, paper, cardboard, corrugated cardboard, plastic, combinations thereof, and other appropriate materials. The chosen material for constructing the packaging member 100 can be any substantially rigid but foldable material. It will be appreciated that, although denominated as rigid or substantially rigid, the chosen material would preferably have an amount of flexibility in the cases of extreme physical impact. In some embodiments, the material used to form the packaging member 100 is a single wall corrugated C-flute cardboard. The illustrated packaging member 100 is a generally thin, planar member; however, the packaging member 100 can have other configurations.

The base member 120 can be sized and dimensioned so as to engage or provide support for one or more articles. Although the base member 120 is described primarily as being disposed at the center of the packaging member 100, the base member 120 can be at other locations. Additionally, the base member 120 can comprise a plurality of members, each configured to engage an article. For the sake of convenience, the base member 120 is described as a generally planar centrally disposed member.

The size of the base member 120, which defines a loading area, can be chosen arbitrarily or to accommodate, support, or engage an article of a particular size. The loading area size can be chosen based on the number and configuration of the articles on or proximate to the base member 120. In some non-limiting exemplary embodiments, the base member can be used to package one or more communication devices (e.g., portable phones, cellular phones, radios, headsets, microphones, etc.), electric devices and components, accessories (e.g., cellular phone covers), storage devices (e.g., disk drives), and the like. In certain embodiments, the base member 120 is configured to package one more portable music players, such as IPODs® or MP3 players.

It is contemplated that the base member 120 can be designed to package any number and type of articles. In the illustrated embodiment, the base member 120 is somewhat square shaped and has a surface area (i.e., the loading area) of about 40-60 inches square. In some non-limiting embodiments, the base member has a loading area more than about 40 inches square, 45 inches square, 50 inches square, 55 inches square, 60 inches square, and ranges encompassing such areas. However, these are merely exemplary embodiments, and the base member 120 can have other dimensions for use in communication devices, packaging modems, hard drives, portable phones, or any other article that is to be packaged.

The illustrated base member 120 has a generally flat upper surface that an article can rest against. Other non-limiting base members can have mounting structures, apertures, recesses, partitions, separators, or other suitable structures for inhibiting movement of an article engaging the base member. For example, the base member 120 can have at least one holder that is sized and configured to receive an article.

The lateral wall portions 140, 142 are positioned on either side of the base member 120. The lateral wall portions 140, 142 can be folded upwardly and inwardly to form lateral side walls.

The lateral wall portion 140 can include a lateral wall protrusion 146 and a flap 148. The wall section 150 can be interposed between the protrusion 146 and the flap 148. The lateral wall protrusion 146 can extend laterally and inwardly from the wall section 150. The flap 148 extends laterally and outwardly from the wall section 150. The protrusion 146 and the flap 148 are medially positioned along the packaging member 100.

At least one fold line can be defined between the lateral wall portion 140 and the base member 120. In the illustrated embodiment, a fold line 160 extends between the base member 120 and the lateral wall portion 140. The fold line 160 also extends partially through the foldable portions 130, 132.

The lateral wall portion 142 can include a lateral wall protrusion 161 and a flap 162. A wall section 164 can be interposed between the lateral wall protrusion 161 and the flap 162. The lateral wall portions 140, 142 can be generally similar to each other and, accordingly, the description herein of one of the lateral wall portions applies equally to the other, unless indicated otherwise.

The fold lines can be formed as perforations in the packaging member 100, i.e., broken cut lines passing partially or completely through the material forming the packaging member 100. In the alternative, or in addition, the fold lines can be crushed portions of the material forming the member 100. Of course, depending on the material used to construct the packaging member 100, the fold lines can be formed as mechanical hinges, thinned portions, adhesive tape, or any other appropriate mechanical connection which would allow various portions of the foldable member to be folded or rotated with respect to each other. These concepts apply to all the fold lines described herein, although this description will not be repeated with respect to the other fold lines described below.

The projections 146, 161 are somewhat rectangular in shape. The projection 146, 161 are merely one type of configuration that can be provided for spacing the base member 120 from a support surface, such as an inner surface of a container, when the base member is in a fully folded configuration. An aperture is formed, at least in part, by the protrusion 146. The illustrated aperture 147 is interposed between the protrusion 146 and the base member 120. As such, the protrusion 146 can be moved relative to the base member 120. An aperture 148 is similarly formed between the protrusion 161 and the base member 120.

Optionally, other protrusions can be used to space other portions of the packaging member 100 from surfaces. The illustrated packaging member 100 has protrusions 180, 182. The protrusion 180 is disposed between the foldable portion 130, the base member 120, and the lateral wall portions 140. The protrusion 182 is disposed between the foldable portion 130, the base member 120, and the lateral wall portions 142. Protrusions 184, 186 are formed in a similar manner by the foldable portion 132, the base member 120, and the lateral wall portions 140, 142.

The foldable portion 130 can be folded downwardly about the fold line 190 towards a bottom surface base member 120. When the foldable portion 130 is folded, it can be approximately parallel to the base member 120. In some embodiments, the foldable portion 130 can lie against the base member 120. The foldable portion 132 can be folded in a similar manner about the fold line 192. Thus, the foldable portions 130, 132 can be folded along the fold lines 190, 192, respectively, and pressed against the bottom surface of the base member 120.

The foldable portions 130, 132 can include a mounting portion 200, 202, respectively, that are configured to interact with a resilient member such that the resilient member and the base member 120 cooperate to securely hold one or more articles. The mounting portion 200 includes a pair of slots 204, 206 that extend at least partially through the foldable portion 130. In some embodiments, including the illustrated embodiment, the slots 204, 206 are elongated slots define lateral edges of an insertable section 210. The mounting portion 202 has a pair of slots 213, 215 that define at least a portion of the insertable portion 220. The insertable sections 210, 220 each can be configured to hold at least a portion of a resilient member.

In some embodiments, each insertable section 210, 220 can be configured to fit into a corresponding pocket of a resilient member. The insertable sections 210, 220 can securely hold and tension the resilient member by folding foldable portions 130, 132 along the fold lines 190, 192, as described in greater detail below. The insertable sections 210, 220 preferably cooperate to tension the resilient member so as to resiliently support one or more articles against the base member 120.

Optionally, extreme ends of the fold line 160, identified generally by the reference numerals 232, 234, can be cuts extending completely through the material forming the packaging member 100. As such, tabs 236, 238 can mate with the outer surface of the protrusion 146 when the packaging member 100 is folded. Cuts 240, 242 are defined at the ends of the fold line 166 and define tabs 244, 246, respectively.

FIG. 2 illustrates an exemplary embodiment of a resilient member 270 that can be mounted to the packaging member 120. Generally, the resilient member 270 can be disposed over at least a portion of the packaging member 100. The insertable sections 210, 220 can be disposed in corresponding pockets 274, 276 of the resilient member 270.

The resilient member in the illustrated embodiment is identified as a retention member 270. The retention member 270 preferably is formed of a resilient body 272. For purposes of convenience for the following description, the body 272 is identified as having a mid point M positioned in the vicinity of the middle of the resilient body 272. The resilient body 272 also includes pockets 274, 276 at opposite ends thereof. In the illustrated embodiment, the retention member 270 is formed of a single piece of resilient material, and is sized to cooperate with the foldable portions 130, 132 of the packaging member 100.

In the illustrated embodiment, the pockets 274, 276 are formed of folds 278, 280 formed in the resilient body 272 which have been attached (e.g., heat sealed, bonded, fused, welded, etc.) along lateral opposite edges thereof. In this embodiment, a heat sealing process forms the heat sealing lines 282, 284, 286, 288. The heat sealing lines 282, 284, 286, 288 can be continuous or formed of a plurality of heat sealed points.

One of ordinary skill in the art will appreciate that there are numerous methods for forming pockets in a resilient sheet material such as the resilient body 272. However, it has been found that heat sealing is particularly advantageous as it does not require expensive adhesives and the time consuming steps required for using such adhesives. However, such adhesives can be used if desired. Welding processes (e.g., induction welding), fusing techniques, and the like can also be used to form the lines 282, 284, 286, 288.

The retention member 270 has a length L₁ that is sized depending on the other devices with which the retention member 270 is to cooperate. Thus, the length L₁ can be sized such that when the retention member is in its final state, e.g., engaged with the foldable portions 130, 132, it generates the desired tension for the corresponding application. Thus, the length L₁ will be smaller where a higher tension is desired and will be larger where a lower tension is desired. Additionally, the length L₁ might be different for different sized articles that are to be packed. One of ordinary skill in the art can determine the length L₁ for the corresponding application.

The retention member 270 can be formed of any resilient material. In some embodiments, the retention member 270 can be made of a polyethylene film. However, virtually any polymer, elastomer, or plastic film can be used to form the retention member 270. The density of the film can be varied to provide the desired retention characteristics such as overall strength, resiliency, and vibrational response. Preferably, the density of the retention member 270 is determined such that the retention member 270 is substantially resilient when used to package a desired article. The retention member 270 can be mono-layer or multi-layer sheet depending on the application.

With reference to FIG. 3, a suspension package assembly 281 includes the packaging member 100 and the retention member 270 connected thereto. An article 300 is securely held between the member 270 and the base member 120 (see FIG. 6). The retention member 270 is preferably permanently mounted to the packaging member 100.

The insertable sections 210, 220 are positioned within corresponding pockets 274, 276. The pockets 274, 276 of the retention member 270 can be placed over the insertable sections 210, 220. The length between the outer edges (i.e., the length of the packaging member 100) of the insertable sections 210, 220 can be slightly greater than the length L₁ of the retention member 270. The sealing lines of the retention member 270 can be disposed along the elongated slots 291, 293 of the packaging member 100. The article 300 can be inserted between the member 270 and the base member 120 after the member 270 is mounted to the base member 120.

The assembly 281 can include at least one coupling structure configured to aid in keeping the packaging member 100 connected to the retention member 270. In some embodiments, the packaging member 100 can include one or more coupling structures (e.g., 297, 299) configured to inhibit movement between the retention member 270 and the packaging member 100.

Each of the coupling structures 297, 299 can include at least one mounting aperture for receiving at least a portion of the retention member 270. The mounting portions 200, 202 can also have at least one aperture for forming at least a portion of a coupling assembly. The illustrated mounting portions 200, 202 each have a corresponding aperture 300, 302 that forms at least a portion of a coupling assembly. The mounting apertures are configured to engage a coupler that inhibits relative movement of the retention member 270 with respect to the packaging member 100. The illustrated coupling structures 297, 299 have a single aperture 300, 302, respectively.

As shown in FIG. 4, when the pockets 274, 276 are engaged with the mounting portions 200, 202, parts of the pockets are disposed on opposite sides of the mounting portions. In this arrangement, as shown in FIG. 4, the retention member 270 has a first sheet 306 and a second sheet 308 on opposite sides of the corresponding mounting portion.

In other words, a portion of the packaging member 100 that defines the aperture 302, in this case the mounting portion 202, is positioned between the first sheet 306 and the second sheet 308. A coupler 310 of the coupling assembly 299 connects the first sheet 306 and the second sheet 308, and is positioned within the aperture 302. This provides a further advantage in securing the retention member 270 to the packaging member 100. As such, the complete assembly 218 can be shipped to a customer, with the retention member 270 securely connected to the packaging member 100, thereby avoiding the need for the ultimate customer to assemble the packaging member 100 to the retention member 270.

In some embodiments, the coupler 310 can be in the form of a heat seal that can cooperate with the aperture 302 to limit movement of the retention member 270. The heat seal 310 can be formed by a heat sealing process, thermal bonding, fusion, adhesives, and the like. In some embodiments, the heat seals are formed from the material forming the sheets 306, 308.

The heat seal 310 can include one or more heat sealing lines, heat sealed points, or other type of coupling structure. The illustrated heat seal 310 is positioned within the aperture 302. A skilled artisan can select an appropriately sized heat seal 310 to pass through the aperture 302 while maintaining the desired bond between the first sheet 306 and the second sheet 308 during the assembly of the package.

Other configurations can be employed to inhibit movement of the retention member 270 with respect to the packaging member 100. Mechanical fasteners, snaps, closures, or other structures can be used to couple the retention member 270 to the packaging member 100. These can be used alone or in combination with heat seals and/or apertures. For example, the coupling assemblies 297, 299 can be in the form of fasteners that pass through the packaging member 100.

Heat sealing, however, provides yet a further improvement because heat sealing is easily incorporated into manufacturing lines for corrugated cardboard. For example, as raw corrugated cardboard pieces are moved along an assembly line, in which dies are used to cut the raw cardboard into the desired shapes, such a packaging member 100, a retention member, such as a retention member 270, can be placed on the packaging member 100 and heat sealed to it with heat sealing devices. A number of thusly finished assemblies 218 can then be packaged in a box and shipped to the customer with little or no human interaction.

In some embodiments, with reference again to FIG. 4, the apertures 300, 302 can be positioned in the folding portions 130, 132. However, the apertures 300, 302 can be at other locations. Additionally, any number of apertures can be utilized. For example, a plurality of apertures can be positioned at various points along the foldable portions 130, 132. In some embodiments, the foldable portions 130, 132 each have at least two apertures. Each of the apertures preferably interacts with at least one heat seal or other coupling structure.

The apertures 300, 302 can have any suitable shape for receiving a heat seal. The illustrated apertures have are somewhat rectangular. In alternative embodiments, the apertures have are circular, elliptical, polygonal (including rounded polygonal) or other shape as desired.

The retention member 270 remains retained to the packaging member 100 even when the packaging member 100 is manipulated. As such, the retention member 270 can be secured to the packaging member 100 before or after the article is positioned between the retention member 270 and the packaging member 100, Additionally, the retention member 270 remains coupled to the packaging member 100 during, e.g., transportation of the assembled suspension package assembly 281.

The package assembly 281 can be folded from the illustrated generally flat configuration of FIGS. 3-5 to tension the retention member 270. FIG. 6 illustrates the foldable portions 130, 132 being folded downwardly along the folding lines 190, 192, respectively, thereby tensioning the retention member 270. The coupling assemblies 297, 299 hold the resilient member 270 to the packaging member 100 as the foldable portions 130, 132 are folded.

The foldable portion 130 can be rotated in the directed by the arrows 322 from the unfolded position 326 to the folded position 328. The foldable portion 132 can be rotated in the directed by the arrows 332 from the unfolded position 336 to the folded position 338. The folded positions 328, 338 can be the maximum limit of rotation.

With reference to FIGS. 6 and 7, the foldable portions 130, 132 in the folded position can lie against the bottom surface 340 of the base member 120. In some embodiments, the retention member 270 is stretched when the foldable portions 130, 132 are moved from the unfolded positions 326, 336 to the folded positions 328, 338, The tensioned retention member 270 can tightly hold the article to the upper surface 341 of the base member 120.

The length L₁ of the retention member 270 can be decreased or increased to increase or decrease the tensioning of the retention member 270. As shown in FIG. 7, the protrusions 180, 182 can capture the retention member 270 therebetween. The retention member 270 can also be captured between the protrusions 184., 186. The protrusions 180, 182, 184, 186 can cooperate to inhibit lateral movement of the edges 313, 315 of the resilient member 270.

With reference to FIG. 8, in some embodiments, the lateral wall portions 140, 142 can be folded upwardly an inwardly along the fold lines 160, 166 as indicated by the arrows 350. As the lateral wall potions 140, 142 are moved upwardly, the protrusions 146, 161 are moved correspondingly downwardly beneath the base member 120. As shown in FIG. 9, the lateral wall portions 140, 142 can be in a generally upright position. In the illustrated embodiment, the wall sections 150, 151 are generally perpendicular to the base member 120. The lateral wall portions 140, 142 and the corresponding protrusions 146, 161 in the illustrated positions form lateral side walls 373, 375. The lateral walls 373, 375 can be generally perpendicular to the base member 120.

The flaps 148, 162 can be folded inwardly and downwardly along the fold lines 362, 368 (FIG. 1) and can extend inwardly from the upper end of the wall sections 150, 151, respectively. In such an embodiment, the base member 120 and the lateral wall portions 140, 142 cooperate to form a space 370 dimensioned so as to accommodate one or more articles to be packaged. In such an arrangement, the article 300, within the space 370, is protected by the side walls 373, 375 and the base member 120. The article 300 is preferably spaced from the lateral wall portions 140, 142 to further protect the article 300 from external forces. The size and configuration of the space 300 can be chosen by one of ordinary skill to effectively minimize impacts to the article 300 which is retained in the package assembly 281.

The base member 120 extends laterally between the side walls 373, 375. The base member 120 is preferably positioned above the edges 380, 382. The protrusions 146, 161 each have a length that is sized depending on the article 300. If the article 300 causes flexing or bending of the base member 120, the length of each protrusions 146, 161 can be selected to minimize or prevent contact between the bottom surface 340 of the base member 120 and another surface of, e.g., packaging.

For example, the base member 120 can be separated from the bottom 391 of the container 400 as shown in FIG. 11. Thus, the protrusions can be sized such that when the packing assembly 281 is in a container, the base member 120 does not contact the container, even when subjected to vibrations, sudden accelerations, etc. In some non-limiting embodiments, the protrusions 146, 161 have a length of about 0.1 inch, 0.2 inch, 0.25 inch, 0.3 inch, 0.5 inch, 0.75 inch, and ranges encompassing such lengths. In such embodiments, the article can be effectively protected as the base member 120 is adequately spaced from the surface 391 of the container 400. However, protrusions of other lengths and shapes can also be employed.

The base member 120 and the foldable portions 114, 116, which lie against the bottom surface of the base member 120, can cooperate to form a shock absorbing structure beneath the panel 112. That is, the foldable portions 114, 116 reinforce the base member 120.

With reference to FIG. 11, the package assembly 281 can be positioned within a container 400. The container 400 can be configured to transport articles of various configurations. The container can be a shipping container, box, or other suitable packaging container. The container 400 can comprise pulp, paper, cardboard, corrugated cardboard, plastic, combinations thereof, and other appropriate materials.

The article 300 can be suspended from the inner surfaces of the container 400. If the container 400 is rapidly accelerated (e.g., the container 400 and package assembly 281 therein are dropped on the ground), the packaging assembly 281 can protect the article 300. That is, the article 300 can be held securely by the packaging assembly 281 away from the inner surfaces of the container 400, even if there shocks imparted to the container 400 during loading, transit, and/or unloading. The packaging assembly 281 may also advantageously absorb energy (e.g., absorb shocks and/or impacts) to minimize energy transferred to the article 300.

Similarly, the side walls 373, 375 are configured such that the article 300 is separated from the top surface 393 of the container 400. Preferably, the article 300 is suspended securely somewhat midway between the opposing inner surfaces 391, 393 of the container 400. The tensioned retention member 270 inhibits movement of the article 300 relative to the base member 120. The tensioned retention member 270 may advantageously absorb vibrations to further protect the article.

The packaging assembly 281 can have various configurations. The illustrated packaging assembly 281 has a somewhat H-shape as viewed from the side. The end 397 of the base member 120 is connected to the lateral side wall 373. The end 399 of the base member 120 is connected to the lateral side wail 375. The ends 397, 399 are preferably positioned somewhat midway along the lateral side walls 373, 375. That is, the ends 397, 399 of the base member 120 can be spaced from the top and bottom of the lateral walls 373, 375. As such, the lateral side walls 373, 375 can extend vertically on either side of the base member 120.

The container 400 can have any number of packaging assemblies. The illustrated container 400 has a single packaging assembly 281. However, the container 400 can be configured to hold a plurality of packaging assemblies. For example, the container 400 can be sized to accommodate packaging assemblies that are in a vertically stacked arrangement. The packaging assemblies can be in any suitable array for placement in a container.

The packaging assembly 281 can be shipped in the flat and unfolded state as illustrated in FIG. 3. These packaging assemblies 281 can be conveniently stacked. The packaging assemblies 281 can then be densely packed in a tight arrangement allowing a large number of packaging assemblies 281 to be transported and at relatively low cost. Alternatively, the retention members and the packaging members can be stored and transported separately. The retention members and the packaging members can be assembled before being used for packaging articles.

The packaging assemblies 281 can also be stacked in a display structure. Space is a premium commodity in the retail, packaging, and shipping industries. Unused floor or wall space costs the money in lost opportunity. Accordingly, it is important to use as much store space as possible to sell merchandise (either assembled or unassembled packaging assemblies). The densely stacked packaging assemblies 281 can maximum self space and may lead to increased sales. The packaging assemblies 281 can be held in free standing display racks, display cabinets, and various wall and shelving configurations. Various manufacturing processes can be employed to form the packaging assemblies.

FIG. 12A illustrates a packaging system 460 that is configured to attach a sheet 462 to the packaging member 100. The sheet 462 can be the starting material to form the retention member 270. The packaging system 460 can form one or more heat seals between portions of the sheet 462 on either side of the packaging member 100. In some embodiments, including the illustrated embodiment, the sheet 462 can be positioned around the member 100 such that the packaging system 460 can form the resilient member 270 while also coupling the retention member 270 to a packaging member 100. This provides yet another advantage in that the retention member 270 can be formed and attached to the packaging member 100 in a one-step process reducing fabrication time and cost.

With continued reference to FIG. 12A, the packaging system 460 can have an upper movable portion 461 and a lower movable portion 463, each being movable between a closed position and an open position. The upper movable portion 461 has a first section 470 a and a second section 472 a. The lower movable portion 463 has a first section 470 b and a second section 472 b. Each of the sections 470 a, 470 b, 472 a, and 472 b comprises a sealing element for forming one or more heat seals. The movable sections 470 a, 470 b include corresponding sealing elements 482, 480 that cooperate to form a heat seal from the sheet 462. Each element can be mounted to an actuator 451. In some embodiments, the sealing elements 480, 482 come together to form the pocket 274 (FIG. 2) of the resilient member.

In the illustrated embodiment of FIG. 12A, the sheet 462 is a sheet that is wrapped around the packaging member 100. The sheet 462 extends across the upper surface of packaging member 100 and along the periphery of the bottom surface of the packaging member 100. To form the sealing lines 288, 286 of FIG. 2, the elements 482, 480 can be brought together. As shown in FIG. 12B, the elements 482, 480 are in a closed position for forming the sealing lines. Optionally, the elements 482, 480 can be used to size and cut the resilient member as desired. The elements 482, 480 can have one or more heating elements, welding surfaces, etc.

The heating elements can be at an elevated temperature suitable for forming the sealing lines. The surface of the elements 482, 480 can be heated to a sufficient temperature to cause the portions of the sheet 462 on either side of the packaging member 100 to be sealed together. As such, the resilient member 270 can be simultaneously formed and coupled to the packaging member 100. In alternative embodiments, a separate process can be used to cut and trim the resilient member to the appropriate size.

Alternatively, the resilient member can be pre-formed and then subsequently assembled with the packaging member 100 to form the packaging assembly 281. In other words, the resilient member 270 with the pockets 474, 476 can be assembled with the packaging member 100.

FIGS. 13A-13C illustrate another method of producing the packaging assembly in accordance with the preferred embodiment. Generally, one or more sheets can be used to form a retention member disposed about the packaging member 100. In FIG. 13A, the sheets 500, 502 are separate sheets positioned on either side of the packaging member 100. In some embodiments, the separate sheets 500, 502 are on separate rolls of material and are fed in the same direction as the packaging member 100 is moved during a manufacturing process, for example. In alternative embodiments, a single, unitary sheet can be positioned on both sides of the packaging member 100. That is, a continuous sheet can be folded over the packaging member 100 and used to form the resilient member 531 of FIGS. 15A and 15B.

With reference to FIG. 13A, the packaging member 100 is interposed between a pair of sheets 500, 502. The sheets 500, 502 can be delivered by a feed system that can continuously output sheets sized to fit over at least a portion of the packaging member 100. As noted above, the feed system can have a plurality of rollers that spool the sheets 500, 502. The sheets 500, 502 can have a width corresponding to the width of resilient member (e.g., the resilient member 531 of FIGS. 15A and 15B).

The sheets 500, 502 and packaging member 100 can be positioned within a packing system 501 designed to join at least a portion of the sheet 500 to the sheet 502. As shown in FIG. 13B, the sheets 500, 502 and packaging member 100 are positioned within the packaging system 501 in an open position.

The packaging system 501 includes a first movable portion 510 and a second movable portion 512 each movable between an open position and a closed position. In the illustrated embodiment, the first movable portion 510 and the second movable portion 512 are spaced from the sheets 500, 502. To couple the sheets 500, 502 together, the first movable portion 510 and the second movable portion 512 can be moved to a closed position as illustrated in FIG. 13C.

With continued reference to FIG. 13B, the first movable portion 510 has sealing surfaces 520A, 520B that can be in contact with corresponding sealing surfaces 522A, 522B of the second movable portion 512. The sealing surfaces 520A, 520B, 522A, 522B cooperate to form the retention member. The sealing surfaces 520A, 520B, 522A, 522B can be used to form the heat seals, cut the sheets 500, 502, and/or otherwise form the sheets into a desired configuration.

In some embodiments, when the movable portions 510, 512 occupy a closed position as illustrated in FIG. 13C, the sealing surfaces 520A, 520B, 522A, 522B can be heated and pressed together to seal and couple together the sheets 500, 502. Thus, the packaging system 501 can be used to both attach and form the resilient member in a one-step process. The first movable portion 510 and the second movable portion 512 can then be moved away from each other to the open position. The illustrated fabrication process of FIGS. 13A-13C can be used to form a generally continuous resilient member that is formed on both sides of the foldable member. Of course, the resilient member can be cut from the retention member illustrated in FIGS. 3 and 4.

FIGS. 14A and 14B illustrate a packaging assembly 530 that can produced by the process shown in FIGS. 13A-13C. The resilient member 531 extends on both sides of the packaging member 100. In FIG. 14A, the sheet 500 is positioned on one side of the packaging member 100 and the sheet 502 (FIG. 14B) is on the other side of the packaging member 100. The edges 542, 544 of the resilient member 531 are formed by the sealing edges 520B, 522B of the movable portions 501, 512, respectively. The edges 552, 554 of the resilient member 531 are formed by the sealing edges 520A, 522A of the movable portions 501, 512, respectively.

Optionally, the first movable portion 510 and the second movable portion 512 can simultaneously form the heat seals 551 and the sealing edges 542, 544, 552, 554. Alternatively, the heat seals 551 can be formed subsequently to the forming of the sealing edges. The package assembly 530, for example, can be removed from the portions 510, 512 and the heat seals 551 can be formed in a subsequent process. In some embodiments, the sheets can be coupled to the packaging member 100 so that the sheet remains attached to the packaging member 100 during the folding process. For example, the sheet 602 can be adhered to the lower surface of the packaging member.

FIG. 15 illustrates a modification of the assembly 281, identified generally by the reference numeral 600. The assembly 600 can include a plurality of coupling assemblies 602. The package assembly 600 is generally similar to the package assembly 281, except as described below.

Each coupling assembly 602 can include an aperture 604 and a heat seal 605. At least one of the coupling assemblies 602 can facilitate positioning of the articles 610, even when the packaging assembly 600 is in an unfolded state. The illustrated packaging assembly 600 includes a coupling assembly 602 interposed between the articles 610. In such an embodiment, the coupling assembly 602 tensions the retention member 622 so that the articles 610 are held snuggly against a packaging member 624. The articles 610 can therefore be held securely in place during the folding process.

Although the present inventions have been described in terms of certain embodiments, other embodiments apparent to those of ordinary skill in the art also are within the scope of these inventions. Thus, various changes and modifications may be made without departing from the spirit and scope of the inventions. For instance, various components may be repositioned as desired. Moreover, not all of the features, aspects and advantages are necessarily required to practice the present inventions. 

1-20. (canceled)
 21. A packaging device for packaging an article, the kit comprising: a support member comprising a base and first and second foldable panels connected to the base such that the base is disposed between the first and second foldable panels, each of the first and second foldable panels being substantially rigid, pivotal with respect to the base and configured to rotate with respect to the base about a folding line between a unfold state and a folded state; a resilient retention member comprising a body portion and first and second pockets disposed at opposite sides of the body portion, the first and second pockets being configured to at least partly receive the first and second foldable panels, respectively, to from an assembled state of the support member and the resilient retention member, the body portion being placed over the base in said assembled state such that an article is placed between the base and the body portion, wherein the first foldable panel comprises outer peripheral edges and a void disposed inwardly from the outer peripheral edges; wherein the first pocket comprising first and second layers opposing each other such that at least a portion of the first foldable panel is disposed between the first and second layers in said assembled state, a portion of the first layer and a portion of the second layer being bonded to each other to form a coupler, wherein the void is configured to receive the coupler in said assembled state to limit relative movement between the first foldable panel and the resilient retention member while the first foldable panel rotates between the unfolded and folded states in said assembled state to tension the body portion in said assembled state.
 22. The device of claim 21, wherein the void comprises an aperture formed in the first foldable panel and configured to receive the coupler.
 23. The device of claim 21, wherein the void and the first pocket are configured such that at least a portion of the void is received in the first pocket in the assembled state.
 24. The device of claim 21, wherein the outer peripheral edges of the first foldable panel comprises two side edges, wherein the void is disposed in the middle between the two side edges.
 25. The device of claim 21, wherein the body portion, the first layer and the second layer are formed of a single resilient sheet.
 26. The device of claim 21, wherein the coupler comprises a heat sealing line.
 27. The device of claim 26, wherein the first layer and the second layer are boned at both sides to form side heat sealing lines, the heat sealing line of the coupler and the side heat sealing lines extending in the same direction.
 28. The device of claim 21, wherein the support member is formed of a single piece of cardboard.
 29. The device of claim 21, wherein the base comprises a substantially rigid single panel.
 30. The device of claim 21, wherein the second foldable panel comprises outer peripheral edges and a second void disposed inwardly from the outer peripheral edges; wherein the second pocket comprising third and fourth layers opposing each other such that at least a portion of the second foldable panel is disposed between the third and fourth layers in said assembled state, a portion of the third layer and a portion of the fourth layer being bonded to each other to form a second coupler, wherein the second void is configured to receive the second coupler in said assembled state to limit relative movement between the second foldable panel and the resilient retention member while the second foldable panel rotates between the unfolded and folded states in said assembled state to tension the body portion in said assembled state.
 31. The device of claim 30, wherein the second void comprises a second aperture formed in the second foldable panel and configured to receive the second coupler.
 32. The device of claim 30, wherein the body portion, the first layer, the second layer, the third layer and the fourth layer are formed of a single resilient sheet.
 33. The device of claim 21, wherein the support member and the resilient retention member are configured to form a packaged assembly when the first foldable panel is folded to tension the body portion such that the article is securely retained between the tensioned body portion and the base.
 34. The device of claim 33, further comprising a container which comprises a plurality of walls and configured to contain the packaged assembly, wherein the article of the packaged assembly is spaced from the plurality of walls.
 35. A method of packaging an article, the method comprising: providing the packaging device of claim 21; assembling the support member and the resilient retention member such that the first and second pockets receives the first and second foldable panels, respectively, and that the void coupler receives the coupler; placing an article between the base and body portion; and rotating the first foldable panel with respect to the base from the unfolded state to the folded state to tension the body portion, thereby forming a packaged assembly of the packaging device and the article, wherein the void and the coupler in combination limits relative movement between the first foldable panel and the resilient retention member while the first foldable panel rotates.
 36. The method of claim 35, further comprising placing the packaged assembly in a container which comprises a plurality of walls, wherein the article is spaced from the plurality of walls.
 37. The method of claim 36, wherein the first foldable panel is disposed between base and one of the plurality of walls and resiliently supports the base. 